Multi-layer composite high-voltage insulated wire

Abstract

The utility model discloses a kind of multi-layer composite strong electric wire, the utility model relates to wire technical field, comprising: solid insulation core, the outer wall of the solid insulation core is fixedly wrapped with conductive core, the utility model is provided with multi-layer composite structure, significantly optimize wire comprehensive performance, solid insulation core provides stable base for conductive core, reduce electromagnetic interference and structural deformation;The spiral twisting design of oxygen-free copper wire and tinned copper wire, give consideration to conductivity efficiency and corrosion resistance, improve wire flexibility.Buff transition layer effectively absorbs mechanical stress, avoid insulation layer cracking;Gradient insulation layer realizes the synergic protection of temperature resistance, flame retardant, weather resistance, and firm interlayer combination.Functional protective layer's honeycomb hole design gives consideration to lightweight and impact resistance, protective sheath layer reinforcement rib then improves torsion resistance and compression resistance, overall solve the problems, such as traditional wire insulation peeling, extreme environment failure, more wide application scene, safety and service life are greatly improved.

Description

Technical Field

[0001] This utility model relates to the field of wire technology, specifically to a multi-layer composite insulated high-strength wire. Background Technology

[0002] In key sectors such as industrial production, new energy equipment, and high-rise buildings, electrical wires, as the core carriers of energy transmission, directly determine the safety of system operation due to their insulation reliability, mechanical strength, and environmental adaptability. With the increasing power of electrical equipment and the growing complexity of application scenarios, traditional insulated wires have gradually revealed many unavoidable technical shortcomings, making them unable to meet current demands for high safety and long service life.

[0003] Existing wires generally adopt the traditional structure of conductor in the center and single-layer or simple multi-layer insulation. The core defects are concentrated in the support stability and electromagnetic compatibility. These wires lack a dedicated central support structure, and the conductors are mostly loosely bundled. When bending the wiring or under long-term vibration, they are prone to displacement and loosening, resulting in uneven current distribution. At the same time, the electric field generated by the conductor when it is working is not effectively shielded, and it is very easy to spread outward and interfere with the surrounding precision electronic equipment, causing hidden dangers. Utility Model Content

[0004] To address the shortcomings of existing technologies, the technical solution adopted by this utility model is as follows: a multi-layer composite insulated high-strength wire, comprising: a solid insulated core, a conductive core fixedly wrapped around the outer wall of the solid insulated core, a buffer transition layer fixedly wrapped around the outer wall of the conductive core, a gradient insulation layer fixedly wrapped around the outer wall of the buffer transition layer, a functional protective layer fixedly wrapped around the outer wall of the gradient insulation layer, and a protective sheath fixedly wrapped around the outer wall of the functional protective layer. The solid insulated core is made of modified epoxy resin and serves as the central support structure of the wire. Breaking away from the traditional centered conductor setting, the solid insulated core provides a stable winding base for the outer conductive core, preventing misalignment or loosening during the stranding process. It not only effectively separates the conductive core from the external structure but also shields the electric field generated by the conductive core during operation from spreading outwards, reducing electromagnetic interference to surrounding electronic equipment. Simultaneously, it improves the overall structural stability of the wire and prevents insulation layer damage due to uneven conductor stress during bending.

[0005] Preferably, the conductive core is formed by stranding oxygen-free copper wire and tin-plated copper wire together and spirally arranged on the outer wall of the solid insulating core. The composite stranding structure of oxygen-free copper wire and tin-plated copper wire ensures efficient current transmission, while the tin-plated copper wire improves corrosion resistance, preventing oxidation of the copper wire during long-term use and thus protecting conductivity. Fixed to the outer wall of the solid insulating core through a spiral winding process, compared to traditional stranded structures, the spiral design enhances the bonding force between the conductive core and the solid insulating core, while also increasing the flexibility of the wire, allowing it to adapt to multi-angle bending in complex wiring environments.

[0006] The buffer transition layer is made of nano-montmorillonite modified EPDM, which is fixedly wrapped around the outer wall of the conductive core. It serves as a flexible bridge between the conductive core and the gradient insulation layer. Its function is to absorb the mechanical stress generated when the wire is bent or pulled, and to prevent the stress from being directly transmitted to the brittle gradient insulation layer, thereby reducing the risk of the insulation layer cracking. At the same time, the flexible nature of the buffer transition layer can fill the surface gaps formed by the spiral winding of the conductive core, so that the outer insulation layer can be uniformly covered and avoid local electric field concentration.

[0007] Preferably, the gradient insulation layer includes a buffer layer, the outer wall of the buffer layer is fixedly wrapped with a core flame-retardant layer, and the outer wall of the core flame-retardant layer is fixedly wrapped with an outer insulation layer.

[0008] Preferably, the outer wall of the outer insulating layer is fixedly connected to the inner wall of the functional protective layer, and the inner wall of the buffer layer is fixedly connected to the outer wall of the conductive core.

[0009] The insulation layer is fixedly wrapped around the outer wall of the buffer transition layer, employing a layered structure of a buffer layer, a core flame-retardant layer, and an outer insulation layer. Each layer provides a specific insulation function, forming a synergistic protection system. The inner wall of the buffer layer is indirectly and fixedly connected to the outer wall of the conductive core through the buffer transition layer. The outer wall of the outer insulation layer is tightly bonded to the inner wall of the functional protection layer. Through the compatibility of the interlayer materials and pretreatment processes, the entire gradient insulation layer is guaranteed to be free from peeling risks, achieving comprehensive insulation protection against temperature, flame retardancy, and weathering. The material of the buffer layer is modified polyimide, the core flame-retardant layer is halogen-free low-smoke flame-retardant polyolefin, and the outer insulation layer is ethylene-tetrafluoroethylene copolymer.

[0010] Preferably, the outer wall of the functional protective layer is provided with honeycomb holes, and the honeycomb holes are linearly arrayed along the central axis of the functional protective layer.

[0011] The functional protective layer is made of a composite structure of high-density polyethylene and steel wire armor, using a spiral armoring process. The honeycomb holes on the outer wall are linearly arrayed along the axis. On the one hand, this reduces the weight of the functional protective layer, enabling lightweight design of the wire and facilitating wiring in high-altitude or complex environments; on the other hand, the honeycomb structure forms a buffer cavity, where the honeycomb holes absorb impact energy through deformation when the wire is subjected to external impact.

[0012] Preferably, the inner wall of the protective sleeve is fixedly connected with reinforcing ribs, and the reinforcing ribs are threaded inside the protective sleeve.

[0013] The protective sleeve is made of modified polyvinyl chloride, possessing excellent wear resistance and weather resistance, with high surface hardness, capable of resisting friction, impact, and outdoor ultraviolet light corrosion during construction. The internally fixed threaded reinforcing ribs are made of glass fiber reinforced nylon, spirally distributed along the inner wall of the protective sleeve, enhancing its torsional strength and preventing internal structural misalignment caused by wire torsion during wiring or use. Simultaneously, the reinforcing ribs disperse the radial pressure on the wire, increasing the compressive strength of the protective sleeve.

[0014] The beneficial effects of this utility model are as follows:

[0015] This invention significantly optimizes the overall performance of the wire through a multi-layered composite structure. The solid insulated core provides a stable base for the conductive core, reducing electromagnetic interference and structural deformation. The spiral stranding design of oxygen-free copper wire and tin-plated copper wire balances conductivity and corrosion resistance, improving wire flexibility. The buffer transition layer effectively absorbs mechanical stress, preventing insulation cracking. The gradient insulation layer provides synergistic protection against temperature, flame retardancy, and weathering, with a strong interlayer bond. The honeycomb design of the functional protective layer balances lightweight and impact resistance, while the reinforcing ribs of the protective sheath enhance torsional and compressive strength. Overall, it solves the problems of insulation stripping and failure in extreme environments common in traditional wires, broadening its applicability and significantly improving safety and service life. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the internal structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the gradient insulating layer of this utility model;

[0019] Figure 4 This is a schematic diagram of the structure of the protective sleeve of this utility model;

[0020] In the diagram: 1. Solid insulating core; 2. Protective sheath layer; 3. Conductive core; 4. Buffer transition layer; 5. Gradient insulation layer; 51. Close to the buffer layer; 52. Core flame retardant layer; 53. External insulation layer; 6. Functional protective layer; 7. Honeycomb holes. Detailed Implementation

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the present invention to the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to better illustrate the principles and practical applications of the present invention, and to enable those skilled in the art to understand the present invention and design various embodiments with various modifications suitable for a particular purpose.

[0022] Example:

[0023] Please see Figure 1 - Figure 4 This utility model provides a technical solution: a multi-layer composite insulated high-strength wire, comprising: a solid insulated core 1, a conductive core 3 fixedly wrapped around the outer wall of the solid insulated core 1, a buffer transition layer 4 fixedly wrapped around the outer wall of the conductive core 3, a gradient insulation layer 5 fixedly wrapped around the outer wall of the buffer transition layer 4, a functional protective layer 6 fixedly wrapped around the outer wall of the gradient insulation layer 5, and a protective sleeve layer 2 fixedly wrapped around the outer wall of the functional protective layer 6.

[0024] The conductive core 3 is formed by stranding oxygen-free copper wire and tin-plated copper wire together and spirally arranged on the outer wall of the solid insulating core 1.

[0025] The gradient insulation layer 5 includes a buffer layer 51, a core flame-retardant layer 52 fixedly wrapped around the outer wall of the buffer layer 51, and an outer insulation layer 53 fixedly wrapped around the outer wall of the core flame-retardant layer 52.

[0026] The outer wall of the outer insulating layer is fixedly connected to the inner wall of the functional protective layer 6, and the inner wall of the buffer layer 51 is fixedly connected to the outer wall of the conductive core 3.

[0027] The outer wall of the functional protective layer 6 is provided with honeycomb holes 7, which are linearly arrayed along the central axis of the functional protective layer 6.

[0028] The inner wall of the protective sleeve layer 2 is fixedly connected with a reinforcing rib 8, and the reinforcing rib 8 is threaded inside the protective sleeve layer 2.

[0029] This invention significantly optimizes the overall performance of the wire through a multi-layered composite structure. The solid insulating core 1 provides a stable base for the conductive core 3, reducing electromagnetic interference and structural deformation. The spiral stranding design of oxygen-free copper wire and tin-plated copper wire balances conductivity and corrosion resistance, improving wire flexibility. The buffer transition layer 4 effectively absorbs mechanical stress, preventing insulation layer cracking. The gradient insulation layer 5 provides synergistic protection of temperature resistance, flame retardancy, and weather resistance, with a strong interlayer bond. The honeycomb hole design 7 of the functional protective layer 6 balances lightweight and impact resistance, while the reinforcing ribs of the protective sleeve layer 2 enhance torsional and compressive strength, comprehensively solving the problems of insulation stripping and failure in extreme environments in traditional wires.

[0030] Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. All other embodiments obtained by those skilled in the art and related fields based on the embodiments of this utility model without creative effort should fall within the protection scope of this utility model. Structures, devices, and operating methods not specifically described and explained in this utility model, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A multi-layer composite insulated high-strength wire, characterized in that, include: A solid insulating core (1) is fixedly wrapped with a conductive core (3) on its outer wall. A buffer transition layer (4) is fixedly wrapped with the outer wall of the conductive core (3). A gradient insulation layer (5) is fixedly wrapped with the outer wall of the buffer transition layer (4). A functional protective layer (6) is fixedly wrapped with the outer wall of the gradient insulation layer (5). A protective sleeve layer (2) is fixedly wrapped with the outer wall of the functional protective layer (6).

2. The multi-layer composite insulated high-strength wire according to claim 1, characterized in that: The conductive core (3) is formed by twisting oxygen-free copper wire and tin-plated copper wire together and spirally arranged on the outer wall of the solid insulating core (1).

3. The multi-layer composite insulated high-strength wire according to claim 1, characterized in that: The gradient insulation layer (5) includes a close-fitting buffer layer (51), the outer wall of which is fixedly wrapped with a core flame-retardant layer (52), and the outer wall of which is fixedly wrapped with an outer insulation layer (53).

4. The multi-layer composite insulated high-strength wire according to claim 3, characterized in that: The outer wall of the external insulating layer is fixedly connected to the inner wall of the functional protective layer (6), and the inner wall of the close-to-buffer layer (51) is fixedly connected to the outer wall of the conductive core (3).

5. The multi-layer composite insulated high-strength wire according to claim 1, characterized in that: The outer wall of the functional protective layer (6) is provided with honeycomb holes (7), which are linearly arrayed along the central axis of the functional protective layer (6).

6. The multi-layer composite insulated high-strength wire according to claim 1, characterized in that: The inner wall of the protective sleeve (2) is fixedly connected with a reinforcing rib (8), and the reinforcing rib (8) is threaded inside the protective sleeve (2).

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